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OPERATION AND MAINTENANCE MANUAL
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Operation and Maintenance Manual
3.5 Ø100+-Valvestab
600135
1” Valve Stab System
600135-TD-0001
01
31
DATE:
CLIENT:
CLIENT PO:
CLIENT DOC NO.:
CONTACT PERSON:
04.09.2012
Copyright  Blue Logic AS
Not to be reproduced or transferred to
others without written permission
Stokkamyrveien 18
Forus
4033 Sandnes
Norway
Phone:+47 91006950
[email protected]
www.bluelogic.no
TECHNICAL DOCUMENT
DOCU MENT
OBJECTIVE
The objective of this document is to present a comprehensive Operation and Maintenance
manual for the Blue Logic designed 1" Valve Stab™ System with outer Stab diameter of
Ø100mm. The System, includes both male and female parts with varying number of hydraulic
ports. All relevant aspects with regards to safe and correct use, installation, operation,
maintenance and storage are covered.
ABSTRACT
The Blue Logic Valve Stab™ System combines the functionality and quality of a ball valve and
a pressure balanced Hot Stab thus forming a reliable field proven leakage free high flow ROV
Stab Connector System. The Valve Stab™ System Program comprises the following main
components:
Male Valve Stab™
Female Valve Stab™ Receptacle
Fail Safe Close/Open System
Cavity flushing system
Protection Stab
Parking receptacle
-
For detailed information with regards to available variants and updated overview of the 1"
Valve Stab Program, please contact Blue Logic.
In general, the Valve Stab™ System is connected and operated as a standard API/ ISO
pressure balanced Hot Stab system. The stab is simply pushed into the receptacle to connect
and pulled out to disconnect. The main difference between the Valve Stab™ and the standard
Hot Stab wrt to operation is that the Valve Stab™ must be inserted into receptacle with
correct alignment. After insertion, the valve function is easy operated by use of the
manipulator.
All operation is performed directly by use of a Standard ROV manipulator.
REVISION CHANGE/RECORD
REV
REASON FOR REVISION/ DESCRIPTION OF CHANGES
01
Issued for Use
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TABLE OF CONTENT
1.
INTRODUCTION ................................................................
........................................................................................
........................................................ 5
1.1.
1.2.
2.
DOCUMENT USE....................................................................................................................... 5
ABBREVIATIONS ....................................................................................................................... 5
TECHNICAL DESCRIPTION
DESCRIPTION ................................................................
....................................................................
.................................... 6
2.1.
2.2.
2.2.1.
2.2.2.
2.2.3.
2.2.4.
2.2.5.
2.2.6.
2.2.7.
2.2.8.
2.2.9.
2.3.
2.3.1.
2.3.2.
2.3.2.1.
2.4.
2.4.1.1.
2.4.2.
2.4.3.
2.4.4.
2.4.5.
2.4.6.
2.4.7.
2.4.8.
2.4.9.
2.4.10.
2.4.11.
3.
3.1.
3.1.1.
3.2.
3.2.1.
4.
4.1.
4.1.1.
GENERAL ..................................................................................................................................... 6
STAB .............................................................................................................................................. 6
Indicator Pin ............................................................................................................................... 7
Stabber Nose ............................................................................................................................. 9
Primary Stab Seal .................................................................................................................... 9
Seal Carrier ................................................................................................................................. 9
Seal Cartridges ....................................................................................................................... 10
Hydraulic Ports ........................................................................................................................12
Flex Joint ....................................................................................................................................12
ROV Handle................................................................................................................................12
Guide Bracket ...........................................................................................................................12
RECEPTACLE ............................................................................................................................13
Outer Housing ......................................................................................................................... 15
Center Core .............................................................................................................................. 15
Seal Cartridges ....................................................................................................................... 15
"COMPENSATOR" PORT ...................................................................................................... 15
ROV/Diver Handle .................................................................................................................. 16
Internal seals ........................................................................................................................... 16
Receptacle Operation Interface ........................................................................................ 17
Bracket/ securing interface............................................................................................... 18
Hydraulic Ports Receptacle ............................................................................................... 18
Receptacle Top Plate ............................................................................................................ 18
Orientation Groove ................................................................................................................ 19
Optional 'Fail Safe Close Actuator .................................................................................. 20
Optional Connection Flushing System ......................................................................... 20
Flushing using Hydraulic Supply Directly from ROV ............................................... 20
Flushing using Blue Logic Valve Stab™ Flushing Unit ............................................ 20
INSTALLATION ................................................................
.......................................................................................
....................................................... 21
RECEPTACLE ............................................................................................................................21
Hydraulic installation .............................................................................................................21
STAB .............................................................................................................................................21
Hydraulic connection.............................................................................................................21
PREPARATION FOR USE ................................................................
.....................................................................
..................................... 22
ONSHORE PREPARATIONS ............................................................................................... 22
Mobilisation check list......................................................................................................... 22
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5.
OPERATION ................................................................
............................................................................................
............................................................ 23
5.1.
5.2.
5.2.1.
5.2.2.
5.3.
5.4.
5.5.
6.
6.1.
6.2.
6.3.
6.4.
6.5.
6.5.1.
6.5.2.
7.
7.1.
7.1.1.
7.2.
OFFSHORE PREPARATIONS ............................................................................................. 23
PRE DIVE CHECK ................................................................................................................... 23
Stab Pre Dive Chk List ......................................................................................................... 23
Receptacle Pre Dive Chk List............................................................................................ 23
SUBSEA CONNECTION........................................................................................................ 24
SUBSEA DISCONNECTION ................................................................................................. 27
POST DIVE CHECK ................................................................................................................. 27
MAINTENANCE ................................................................
......................................................................................
...................................................... 28
GENERAL .................................................................................................................................. 28
WEEKLY MAINTENANCE..................................................................................................... 29
MONTHLY MAINTENANCE ................................................................................................. 29
YEARLY MAINTENANCE ...................................................................................................... 29
SEAL REPLACEMENT........................................................................................................... 30
Main Outer Seal (Stab) ....................................................................................................... 30
Seal Cartridges and spherical core seals (Stab) ...................................................... 30
STORAGE AND TRANSPORT
TRANSPORT ...............................................................
............................................................... 31
STORAGE ....................................................................................................................................31
Preservation for storage ......................................................................................................31
TRANSPORT ..............................................................................................................................31
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1.
INTRODUCTION
The Blue Logic Valve Stab™ is a patented hydraulic connector system combining technology
from standard Hot Stab connectors and Ball Valves into a very compact and lightweight
subsea connector system. The unique features obtained allows for 100% leakage free subsea
connection with full system pressure. Since the system includes built-in valve functionality
both in the stab and receptacle side, subsea valve and connector panels can be designed
extremely compact compared to alternative solutions.
The Valve Stab™ technology is relevant for use in almost all subsea connector applications
and can be easily operated by use of either Diver or ROV. The System is fully pressure
balanced and does not introduce any axial forces into the connector or panel system. When
the system is connected and the ports are opened, the Stab Connector is locked into the
receptacle system automatically.
Despite all included functions, the Valve Stab™ System is a very simple and robust
construction with very few mowing parts. All seals can easily be replaced offshore.
Receptacle seals can even be replaced subsea by use of dedicated seal replacement tool.
This document includes a technical description, sequences and recommendations for safe
operations and relevant aspects for maintenance and storage.
1.1.
DOCUMENT USE
This document shall be used as general information for all aspects related to safe use,
installation, removal, maintenance and storage of the Valve Stab™ System. Included in this
Operation and Maintenance Manual are sequential step-by-step procedures for typical
offshore operations which can be used for establishing detailed specialized offshore/subsea
procedures. These lists can also be used for documentation of performed work and
sequences if required.
The Valve Stab™ System includes different sizes, variants and configurations. For updated
full program overview, please contact Blue Logic AS. This document covers Operation and
Maintenance of the Ø60mm Blue Logic Valve Stab™ program. Additional manuals are
however also available for special variants or client/ project specific designs.
1.2.
ABBREVIATIONS
ROV:
HPU:
FAT:
MOB:
DEMOB:
Remotely Operated Vehicle
Hydraulic Power Unit
Factory Acceptance Test
Mobilisation
Demobilisation
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2.
TECHNICAL DESCRIPTION
DESCRIPTION
2.1.
GENERAL
The Ø100 Valve Stab™ program includes versions with alternative number of hydraulic ports
and configurations. In addition, the complete programs also includes systems with different
number of ports and internal bore. Dedicated technical description and further
documentation is available for different sizes although all Valve Stab™ Systems are based on
the same core technology and will be operated using the same principles.
2.2.
STAB
ROV Handle
Flex Joint
Indicator Pin
Seal Carrier
Primary Stab
Seal
Stabber
Nose
Hydraulic
Port
Guide
Bracket
Body
Figure 1 Ø100 Single Port Valve Stab
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2.2.1. Indicator Pin
The purpose of the Valve Stab™ Indicator pin is to visually confirm correct mating of the Valve
Stab™ into the Receptacle prior to flushing of cavities or operation of the Valve Stab™ Valve
function. The Indicator pin is black and will pop out approx 4mm when the Stab is correctly
mated as illustrated on below figures.
Indicator pin
retracted.
Figure 2 Prior to mating of Stab into Receptacle
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Indicator pin
extracted.
Figure 3 Stab correct mated into Receptacle
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4mm
Figure 4 Indicator Pin movement
2.2.2. Stabber Nose
The Stabber Nose ensures correct and gentle guiding of the Stab into the Receptacle. Stab
noses are normally constructed by use of an Aluminum Bronze alloy or PEHD1000 to protect
the receptacle internals. The Stabber nose is connected to the Stabber by use of threads and
can be unscrewed by use of a Hex umbraco tool. For the Ø100 Valve Stab system, the Hex key
size is 34mm.
The Stabber Nose also secures and locks the Seal Carrier onto the Stab. Therefore correct
installation and tightening of the stabber nose is important and should be verified prior to
operation.
2.2.3. Primary Stab Seal
The Primary Stab Seals separates the different hydraulic ports and seals toward the
receptacle. Different alternative seal profiles and materials are available depending on
application and fluid. Standard Blue Logic seal material is HPUR, which is compatible with
most relevant fluids and have a mechanical properties thus securing for long service life
without need for replacement. The Primary Stab Seals can however easily be replaced
offshore without need for any disassembly of the stab. Please see following sections for
details with regards to seal replacement.
2.2.4. Seal Carrier
All stabber seals are placed in the Valve Stab™ seal carrier, both the internal Core Seals and
the outer Primary Seals. The Seal Carrier is replaced by unscrewing the stabber nose and seal
cartridges. Note: Seal cartridge are secured with Loctite 577 and needs to be heated to
approx. 80-100 deg before unscrewing. Use hot water or air gun to heat. (If air gun is used,
never heat directly on seals)
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Figure 5 Valve Stab™ Seal Carrier with internal and external seals
2.2.5. Seal Cartridges
The Seal Cartridges includes the Spherical Core Seal which seals toward the Valve Stab™
Core placed inside the Seal Carrier. The Seal Cartridges can be unscrewed by use of a 26mm
Hex Unbraco key for replacement or inspection. Please see section for maintenance with
regards to replacement of seal or seal systems.
Note: Seal cartridge are secured with Loctite 577 and needs to be heated to approx. 80-100
deg before unscrewing. Use hot water or air gun to heat. (if air gun is used, never heat directly
on seals)
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Seal Carrier
Seal
Cartridge
Primary Stab
Seal
Figure 6 Stab Seal Carrier and Seal Cartridge
Seal
Cartridges
Spherical
Core Seal
Figure 7 Seal Cartridges removed
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2.2.6. Hydraulic Ports
The Ø100 Valve Stab™ system is delivered with 1 1/4" BSP female hydraulic port.
A mechanical lock for the BSP port effectively secures the BSP connector.
2.2.7. Flex Joint
The Flex Joint connects the Valve Stab™ body to the ROV Handle. It consists of an outer
flexible element and an inner mechanical connection. The Flex Joint allows for a smooth angle
deviation of approx 20 degrees in all directions between the ROV handle and Valve Stab™. The
flex element can easily be replaced, se maintenance section for details wrt to replacement of
flex element.
2.2.8. ROV Handle
The Valve Stab™ can be delivered with different alternative ROV Handles. Most common is the
ROV "D-Handle". ROV Handles can easily be replaced by unscrewing the ROV Handle bolts.
D-handle
Handle
Securing
bolts
Figure 8 ROV Handle
2.2.9. Guide Bracket
The Guide Bracket ensures that the Valve Stab™ is aligned correctly prior to connection into
the Receptacle. The Guide Bracket fit's into the machined Orientation Groove in the
receptacle and once correct inserted triggers the receptacle position lock system.
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2.3.
RECEPTACLE
The Valve Stab™ receptacle consists of the following main parts;
1.
2.
3.
4.
5.
6.
7.
8.
9.
Outer Housing
Inner Centre Core
ROV/Diver Handle
Seal Cartridges
Internal seals
Bracket/ securing interface
Orientation Groove
Hydraulic Ports
Receptacle Top Plate
Inner Centre
Core
Orientation
Groove
ROV/Diver
Handle
Top Plate
Outer
Housing
Hydraulic
Port
Seal
Cartridges
Figure 9 Receptacle
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Green = closed ok to stab and pull out
Red = HOT (open)
Compensator port
Blind port
Figure 10 Receptacle
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2.3.1. Outer Housing
The Outer Housing is constructed by use of hard anodized aluminium. The Outer Housing
includes the hydraulic ports, interface for installation (securing interface) and interface for
seal cartridges as further described in following sections. All Valve Stab™ receptacle seals
are placed inside the Outer Housing.
2.3.2. Center Core
The Inner Center Core rotates inside the Outer Housing thus opening and closing the
hydraulic ports. It is constructed by corrosion resistant high strength alloy to reduce wear and
improve lifetime.
2.3.2.1.
Seal Cartridges
Similar as for the male Valve Stab™, the Seal Cartridges contains the Spherical Cores Seals
which seals towards the Inner Centre Core. The Seal Cartridges is secured by use of Loctite
577 and can be unscrewed by use of a 28mm hex key.
2.4.
"COMPENSATOR" PORT
The compensator port is connected to the Receptacle Output port when the Valve Stab
receptacle is closed. When a Stab is inserted into the receptacle and the Valve Stab ports are
opened (by operating the receptacle ROV handle), this compensator port closes
simultaneously.
Compensator
port
Hydraulic
Connection
Figure 11 Hydraulic schematic Valve Stab w/ compensator port
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2.4.1.1.
ROV/Diver Handle
The ROV handle operates the Valve Stab™ Open/Close function. It is to be rotated in order to
operate the Valve Stab™.
Operate ROV Handle Clockwise (green area)
- The Valve Stab™ valve functions are CLOSED and the stab can be inserted or retracted
from the receptacle
Operate ROV Handle Counter Clockwise (red area,
area , “Hot”)
“Hot”)
- The Valve Stab™ valve functions are OPEN and the stab is LOCKED in position into the
receptacle.
NOTE: The Valve Stab™ must be correct and fully inserted into the Valve Stab™ Receptacle in
order to OPEN
OPEN the Valve Stab™ valve functions.
2.4.2. Internal seals
Valve Stab™ receptacle internal seals are not shown on above figure. The seals are placed on
the inner side of the outer housing. The Center Core will need to be removed from the outer
housing in order to replace the internal seals.
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2.4.3. Receptacle Operation Interface
The Receptacle Operation Interface can thus be used for remote operation of the Valve Stab™
function. Typically this can be achieved by installing a hydraulic, mechanical or electrical
actuator.
Figure 12 Receptacle operation interface
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2.4.4. Bracket/ securing interface
The Bracket Securing interface is used to securing the Receptacle onto the ROV or subsea
equipment.
Figure 13 Receptacle securing interface
2.4.5. Hydraulic Ports Receptacle
The hydraulic ports in the receptacle have the same port size and marking as the Valve
Stab™:
Output Ports:
Compensator port
1-1/4" BSP female
1/2" BSP female
2.4.6. Receptacle Top Plate
The Receptacle Top Plate is bolted onto the Receptacle outer housing. It includes the
Orientation Groove and color marking for Valve Stab™ Valve position.
There are three equal interfaces placed in different orientations on the receptacle for optimal
placement of the receptacle on the equipment.
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2.4.7. Orientation Groove
The Orientation Groove in the Receptacle ensures correct orientation of the Valve Stab™
when inserting into the receptacle. When the Valve Stab™ is fully inserted into the
Receptacle, the Valve Stab™ Guide Bracket activates a Lock Spring in the Orientation Groove
thus allowing for operation of the Valve Stab™ and Receptacle Valve Mechanism.
Figure 14 Valve Stab™ and receptacle mating
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2.4.8. Optional 'Fail Safe Close Actuator
NA
2.4.9. Optional Connection
Connection Flushing System
One of the unique features with the Valve Stab™ System is the ability to perform a 100% clean
subsea multiport connection. The cavity volume trapped between the stab and receptacle is
very small compared with traditional connector systems. In addition, this cavity volume can
be flushed prior to opening the Valve Stab™ ports. There are different ways of performing this
flushing process depending on the Stab/ Receptacle configuration and number of hydraulic
ports. Blue Logic has developed optional special equipment to effective perform this flushing
process.
Figure 15 Alternative 1 Flushing principle
Figure 16 Alternative 2 Flushing principle
In general, the flushing shall be performed by flushing through the receptacle flushing ports
prior to operation of the Valve Stab™ function.
Contact Blue Logic for further information wrt flushing of Valve Stab Cavities
2.4.10. Flushing using Hydraulic Supply Directly from ROV
NA
2.4.11. Flushing using Blue Logic Valve Stab™ Flushing Unit
NA
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3.
INSTALLATION
3.1.
RECEPTACLE
The Receptacle will normally be installed into a ROV Panel by use of a bracket or by use of
bolts direcly.
Receptacle installation interface is as shown on below figure:
Figure 17 Rear End of Valve Stab Receptacle
Note 1: If dedicated CP system is present, ensure that the receptacle is correctly
correctly earthed and
connected to this. Use separate cable if required.
Note 2: The receptacle outer part is made of hard anodized aluminium.
3.1.1. Hydraulic installation
The hydraulic functions shall be connected to the Receptacle hydraulic ports by use of hoses
or piping. Hydraulic ports on the receptacle are described in above Section 2.4.5
3.2.
STAB
3.2.1. Hydraulic connection
Hydraulic connection to the receptacle is performed by use of standard hydraulic BSP
fittings.
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4.
PREPARATION FOR USE
4.1.
ONSHORE PREPARATIONS
Prior to shipping offshore a mobilisation/ verification should be performed. All functions
should be tested and verified. The following check list should be used as a guideline for
activities to be performed prior to offshore mobilisation:
4.1.1. Mobilisation check list
No.
Description
01
02
03
04
05
06
Inspect Stab and receptacle visual
Inspect surface treatment undamaged
Inspect Stab Hydraulic Port Seal areas for damage
Inspect Receptacle Hydraulic port seal areas for damage
Inspect Receptacle seal areas undamaged without scratches
Inspect Stab Guide Bracket undamaged
Inspect Receptacle Orientation groove and verify functionality of the
guide/orientation system.
Verify that the stab and receptacle Valve function can not be operated
prior to mating. Mate Stab and receptacle.
Verify activated indicator pin on stab (approx 4mm extracted)
Verify that the Valve Stab™ valve function can be operated when
connected.
Insert and operated both Stab and receptacle system. Verify smooth
and correct movement of Valve function.
Verify Correct packing and documentation in the transport box. The
transport box should include as a minimum Valve Stab™ system
Operation and Maintenance Manual
07
08
09
10
11
12
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Chk/Verified
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5.
OPERATION
5.1.
OFFSHORE PREPARATIONS
PREPARATIONS
5.2.
PRE DIVE CHECK
Prior to dive, the Valve Stab™ System should be inspected and function tested.
5.2.1. Stab Pre Dive Chk List
No.
Description
Description
01
Perform a visual inspection
- Seals
- Seal Areas
- Fittings
- Hoses
- ROV Handle
- Flex Joint
- Guide Bracket
- Hose Tension Relief
- Hose conditions, pressure rating, lengths and hose protection
Chk/Verified
02
Verify that the Valve Stab™ is closed and cannot be opened prior to
insertion into receptacle
03
Insert the Valve Stab™ into a Valve Stab™ receptacle, ensure smooth
movement and observe friction force.
04
Open the Valve Stab™ System through the ROV/Diver handle. If a fail
safe actuator or similar remote operation mechanism is installed,
verify functionality of this.
05
Close Valve Stab™ and disconnect from receptacle.
06
Inspect Seals and seal areas.
5.2.2. Receptacle Pre Dive Chk List
No.
Description
01
02
03
Visual inspect receptacle internal surface finish and entrance area.
Verify access for ROV and stab into receptacle
Inspect all hoses, piping and fittings for leakage. Pay special
attention to seal system.
Verify that the Receptacle valve function can not be operated when
the Male stab is not inserted into the receptacle.
04
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05
06
07
08
09
5.3.
Insert a Valve Stab™ into the receptacle. Verify correct installation
and access.
Open the Valve Stab™ and receptacle valve function by use of the
ROV/Diver Handle.
If a fail safe close system or a remote operation actuator is installed;
inspect and verify all functions.
Close Valve function and disconnect Valve Stab™ from receptacle
Perform a visual inspection of the receptacle.
SUBSEA CONNECTION
No.
Description
01
Visually inspect Valve Stab™ Receptacle prior to subsea connection.
Verify ROV/ Diver access and general condition of the Valve Stab™
Receptacle in front of, and behind the panel.
02
Inspect Valve Stab™ ROV/ Diver handle. Verify that the Valve Stab™
position is Closed (Green Area) as indicated on figure below.
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03
Start Insertion into receptacle. Use a loose manipulator grip if
possible.
04
Align stab into receptacle and gentle slide/push stab down. Rotate
Valve Stab™ in order to align Stab Guide Bracket and Receptacle
orientation groove. When correct aligned, push the stab down and
fully into the Receptacle. The indicator pin will extract approx 4mm
Guide Bracket
Alignment
Groove
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05
Fully insert the Valve Stab™ into the Receptacle. Ensure correct
engagement of Guide Bracket/Orientation.
Verify indicator pin movement:
4mm
06
Operate Receptacle ROV/Diver handle from CLOSED (Green Position)
COUNTER CLOCKWISE to OPEN position stab system.
Closed Position
(Stab free for insertion)
Open Position
(Stab locked into receptacle)
Note: It is always recommended to open or close without pressure
and flow over the Valve Stab™ system
07
Verify hydraulic ports open and inspect Receptacle/ Stab for
leakages. Operate desired hydraulic functions.
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5.4.
SUBSEA DISCONNECTION
No.
Description
01
Visually inspect Valve Stab™ Receptacle prior to subsea
disconnection. Verify ROV/ Diver access and general condition of the
Valve Stab™ Receptacle in front of, and behind the panel.
02
Close the Valve Stab™ System Valve function by operating the ROV/
Diver handle CLOCKWISE
Open Position
(Stab Locked in Receptacle)
Chk/Verified
Closed Position
(Stab free for removal)
Note: It is always recommended to open ore close without pressure
and flow over the Valve Stab™ system
03
Pull the Valve Stab™ out from the receptacle. Verify no leakages and
perform a visual inspection.
04
Continue with operation
5.5.
POST DIVE CHECK
No.
Description
01
Recover Valve Stab™ equipment to deck.
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02
Perform a visual inspection
-
Seals
Seal areas
ROV Handle
Flex Joint
Hoses and piping
Fittings
Surface treatment
03
Flush all equipment with fresh water
04
Dry off equipment and apply protective oil prior to storage
6.
MAINTENANCE
6.1.
GENERAL
The Valve Stab™ system is a simple and robust Subsea connection system with few critical
moving parts. If moving parts is not filled with salt and sand/ dirt particles, but cleaned and
lubricated, the only parts which will need to be routinely replaced is the seal system.
There are however a few important inspections points which shall be performed routinely in
order to guarantee problem free use and operation of the Valve Stab™ System.
-
MOB/Demob inspection and control
Daily inspection during offshore operations
Weekly routinely inspection during offshore operations
Yearly inspection and Maintenance
All above recommended inspection and maintenance can be performed by operator, it is
however recommended to return the Valve Stab™ System to Blue Logic for a yearly
inspection and maintenance to ensure minimum 20years of problem free use.
For MOB/demob, please see above Section 4.1.1
For Daily inspection during offshore operations; please see above Section 5.2 for pre-dive
activities and Section 5.5 for post dive.
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6.2.
WEEKLY MAINTENANCE
No.
Description
01
Perform a visual inspection of Stab and receptacle. Inspect Surface
treatment and verify no corrosion issues. Special attention should be
to the following:
- Seals
- Seal areas
- ROV Handle
- Flex Joint
- Hoses and piping
- Fittings
- Surface treatment
- Stab Guide Bracket
- Receptacle Orientation Groove
02
Insert the Valve Stab™ into receptacle. Verify correct engagement of
orientation groove, guide bracket and Indicator Pin
03
Operate the Valve Stab™ valve function by use of the ROV/Diver
handle. Verify smooth movement
Close the Valve Stab™ valve function, verify smooth movement
Pull the Valve Stab™ out of the receptacle and verify that the valve
function can not be operated on either the Receptacle or Stab
Ensure protective oil applied and no water/moisture entrapped on
critical parts.
Operate in dedicated aluminium transport box.
04
05
06
07
6.3.
Chk/Verified
MONTHLY MAINTENANCE
No special activities are required on a monthly basis. If the Valve Stab™ system has been
extensively used and repeatedly exposed to dirt and aggressive fluids, all Stabber and
receptacle seals should be inspected and replaced if required.
6.4.
YEARLY MAINTENANCE
No.
Description
01
Inspect all external and internal Valve Stab™ Seals. Replace if
required.
Inspect all external and internal Receptacle Seals. Replace if
required.
Check all mechanical functions, verify smooth operations. Inspect for
scratches and general wear, lubricate all moving parts.
Function test Stab and Receptacle and perform a full leakage test.
02
03
04
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6.5.
SEAL REPLACEMENT
6.5.1. Main Outer Seal (Stab)
Sequence for replacement of the Main Outer Stab Seals:
No.
Description
01
Remove old seals by use of a sharp knife. Cut the seals, but be very
carefully not to damage seal surfaces.
Heat the new seals to 80-100 degrees using hot water.
02
03
Chk/Verified
Stretch the new seals gently by hand. Slide the seals over the outer
stab body. Use water or oil to lubricate.
As an option; a dedicated Seal Replacment Tool is available. Please contact Blue Logic for
further details.
6.5.2. Seal Cartridges and spherical core seals (Stab)
During normal use, the seal spherical core seals does not need to be replaced. They will be
inspected and replaced if required during the recommended yearly service. If however the
seals are to be replaced offshore, please follow the following sequence:
No.
Description
Description
01
Clean all parts thoroughly prior to start-up
To unscrew the seal cartridges, first heat parts to 80 degrees to
loosen the Locktite 577 used to secure the threads. Use hot water or
an air heat gun.
Use a 26mm Hex key to unscrew the seal cartridges.
Inspect all threads and inner core seal surfaces
Remove the Spherical Core Seals from the seal cartridges
Clean and inspect all seal surfaces
Clean threads and remove old loctite carefully.
Install new seals onto the seal cartridges
Apply a small drop of Loctite 577 on seal cartridge threads.
Apply a thin film of oil on the seals
Verify that the seal cartridge threads enters correctly into the Seal
Carrier female threads. Use "finger torque" only and verify that the
seal cartridges can be rotated to end stop by hand.
Apply 15 Nm to secure
Perform a complete functional testing of the Valve Stab™ System
Pressurise to design pressure and verify no leakages.
02
03
04
05
06
07
08
09
10
11
12
13
14
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7.
STORAGE AND TRANSPORT
TRANSPORT
7.1.
STORAGE
7.1.1.
No.
01
02
03
7.2.
Preservation for storage
Description
Visual inspect the Hot Stab for damages and wear.
Ensure correct post dive sequence followed (se above sections)
Apply preservation oil and secure in storage box.
Chk/Verified
TRANSPORT
TRANSPORT
No special precautions are needed for transport. However, the following should be verified:
Correct packing; preferably by use of aluminium transport box
Verify the following
1. Sender Name and Address clearly visible
2. Receiver Name and address clearly visible
3. Inventory list correct filled out
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